Fire barrier layer and fire barrier film laminate

ABSTRACT

A fire barrier laminate including: at least one non-fibrous fire barrier layer directly or indirectly coated onto at least one first polymeric flame propagation resistant film layer; at least one second film layer proximate to the non-fibrous fire barrier layer opposite the first polymeric flame propagation resistant film layer; at least one scrim layer disposed: (i) between the non-fibrous fire barrier layer and the first polymeric flame propagation resistant film layer; and/or (ii) between the non-fibrous fire barrier layer and the second film layer; and/or (iii) proximate to the first polymeric flame propagation resistant film layer opposite the non-fibrous fire barrier layer; and/or (iv) proximate to the second film layer opposite the non-fibrous fire barrier layer. Also, a method of making the fire barrier laminate.

This application claims the benefit of the filing date under 35 U.S.C.119(e) from United States Provisional Application For Patent Ser. No.61/415,552 filed on Nov. 19, 2010.

A fire barrier laminate is provided for use in thermal and acousticalinsulation systems, such as, but not limited to, those used incommercial aircraft.

The Federal Aviation Administration (FAA) has promulgated regulations,contained in 14 C.F.R. §25.856(a) and (b), requiring thermal andacoustical insulation blanket systems in commercial aircraft to provideimproved burn through protection and flame propagation resistance. Theseconventional thermal and acoustical insulation systems typically includethermal and acoustical insulation blankets encapsulated within a filmcovering or bag. As the thermal and acoustical insulation systems areconventionally constructed, the burn through regulations primarilyaffect the contents of the insulation systems' bags and the flamepropagation resistance regulations primarily affect the film coveringsused to fabricate the bags. Conventional film coverings typically areused as a layer or covering, for example, laid over or laid behindlayers of thermal and acoustical insulation material, or as a coveringor bag for partially or totally encapsulating one or more layers ofthermal and acoustical insulation material.

FIG. 1A is a schematic cross-sectional view of a thermal and acousticalaircraft insulation blanket protected by an embodiment of the subjectfire barrier laminate.

FIG. 1B is an exploded cross-sectional view of an illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 1C is an exploded cross-sectional view of another illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 1D is an exploded cross-sectional view of a further illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

FIG. 1E is an exploded cross-sectional view of a further illustrativeembodiment of the subject fire barrier laminate circled portion B′ ofthe embodiment of FIG. 1A.

A fire barrier layer is provided which is incorporated into a firebarrier laminate for use in thermal and acoustical insulation systems,such as, but not limited to, those used in commercial aircraft. By wayof example, but not limitation, the fire barrier laminate may be used asa covering that is located between insulation material in fuselage wallcavities and the outer skin of an aircraft fuselage (as an outboardcover of an insulation system) and/or between insulation material infuselage wall cavities and the interior aircraft trim panels (as aninboard cover of an insulation system).

The incorporation of the subject fire barrier layer in a fire barrierlaminate, used for protecting thermal and acoustical insulationstructures, solves problems previously associated with the use oflightweight ceramic or inorganic papers, which tend to be fragile tohandling or in use where harsh mechanical environments are encountered.

In certain embodiments, the subject fire barrier film laminate comprisesat least one non-fibrous fire barrier layer coated onto at least onefilm layer, optionally a water-repellant material incorporated intoand/or applied to the fire barrier layer, at least one scrim layer, atleast one second film layer, and optionally at least one adhesive layer,the non-fibrous fire barrier layer comprising at least one inorganicplatelet material, optionally at least one organic binder and/orinorganic binder, and optionally at least one functional filler.

In certain embodiments, the fire barrier laminate comprises: at leastone non-fibrous fire barrier layer directly or indirectly coated onto atleast one first polymeric flame propagation resistant film layer; atleast one second film layer proximate to the non-fibrous fire barrierlayer opposite the first polymeric flame propagation resistant filmlayer; at least one scrim layer disposed: (i) between the non-fibrousfire barrier layer and the first polymeric flame propagation resistantfilm layer; and/or (ii) between the non-fibrous fire barrier layer andthe second film layer; and/or (iii) proximate to the first polymericflame propagation resistant film layer opposite the non-fibrous firebarrier layer; and/or (iv) proximate to the second film layer oppositethe non-fibrous fire barrier layer; optionally, a water-repellantmaterial incorporated into and/or applied to the non-fibrous firebarrier layer; optionally at least one adhesive layer adhering thenon-fibrous fire barrier layer to the first polymeric flame propagationresistant film layer; and optionally at least one adhesive layeradhering the scrim layer to at least one of the non-fibrous fire barrierlayer, the first polymeric flame propagation resistant film layer, orthe second film layer; wherein the non-fibrous fire barrier layercomprises at least one inorganic platelet material, optionally at leastone organic binder and/or inorganic binder, and optionally at least onefunctional filler. Optionally, the second film layer may also be flamepropagation resistant.

By indirectly coating, it is meant that the non-fibrous fire barrierlayer may be coated onto an intermediate layer, such as a scrim, whereinthe intermediate layer is engaged with the first polymeric flamepropagation resistant film layer. The intermediate layer may be engagedwith the first polymeric flame propagation resistant film layer beforeor after being coated with the non-fibrous fire barrier layer.

This composition provides a light basis weight article with surprisingresistance to damage associated with handling and use along with theability to resist flame propagation and flame penetration as defined in14 C.F.R. §25.856(a) and (b). The term “basis weight” is defined as theweight per unit area, typically defined in grams per square meter (gsm).The subject fire barrier layer, and the laminate incorporating it, aretherefore useful in providing fire burn-through protection for thermaland acoustical insulation structures, referred to in the industry as“blankets”, for commercial aircraft fuselages, as the subject firebarrier laminate may have a basis weight of between about 80 gsm toabout 120 gsm, and in certain embodiments between about 90 gsm to about110 gsm.

The inorganic platelet material of the fire barrier layer may compriseat least one of vermiculite, mica, clay or talc. While any sizeinorganic platelet material may be used, inorganic platelet materialswith larger relative diameters and high diameter to thickness aspectratios may be desirable due to their increased flame propagation and/orburnthrough resistance performance, as well as other properties such asflexibility and processibility. In certain embodiments, the inorganicplatelet material may have a diameter of from about 20 μm to about 300μm. In further embodiments, the inorganic platelet material may have adiameter of from about 40 μm to about 200 μm. In certain embodiments,the inorganic platelet material may have an aspect ratio of from about50:1 to about 2000:1. In certain embodiments, the inorganic plateletmaterial may have an aspect ratio of from about 50:1 to about 1000:1. Infurther embodiments, the inorganic platelet material may have an aspectratio of from about 200:1 to about 800:1.

The vermiculite or mica may be exfoliated, and may further bedefoliated. By exfoliation, it is meant that the vermiculite or mica ischemically or thermally expanded. By defoliation, it is meant that theexfoliated vermiculite or mica is processed in order to reduce thevermiculite or mica to substantially a platelet form. Vermiculite may beincluded in the fire barrier layer in an amount from about 20 to about100 weight percent, based on the total weight of the fire barrier layer.

Suitable micas may include, without limitation, muscovite, phlogopite,biotite, lepidolite, glauconite, paragonite and zinnwaldite, and mayinclude synthetic micas such as fluorophlogopite. Mica may be includedin the fire barrier layer in an amount from about 20 to about 100 weightpercent, based on the total weight of the fire barrier layer.

Suitable platelet clay materials that may be included in the firebarrier layer include, without limitation, ball clay, bentonite,smectite, hectorite, kaolinite, montmorillonite, saponite, sepiolite,sauconite, or combinations thereof. Platelet clay materials may beincluded in the fire barrier layer in an amount from about 5 to about 60weight percent, in certain embodiments from about 5 to about 50 weightpercent, based on the total weight of the fire barrier layer.

The mica, vermiculite and/or clay platelet materials may also becombined with further platelet materials, such as talc. If present, talcmay be included in the fire barrier layer in an amount from about 1 toabout 50 weight percent, in certain embodiments, from about 10 to about30 weight percent, based on the total weight of the fire barrier layer.

The fire barrier layer may include inorganic binders. Withoutlimitation, suitable inorganic binders include colloidal dispersions ofalumina, silica, zirconia, and mixtures thereof. The inorganic binders,if present, may be used in amounts ranging from 0 to about 40 percent byweight, in some embodiments from 0 to about 20 weight percent, basedupon the total weight of the fire barrier layer.

The fire barrier layer may further include one or more organic binders.The organic binder(s) may be provided as a solid, a liquid, a solution,a dispersion, a latex, or similar form. Examples of suitable organicbinders include, but are not limited to, acrylic latex, (meth)acryliclatex, phenolic resins, copolymers of styrene and butadiene,vinylpyridine, acrylonitrile, copolymers of acrylonitrile and styrene,vinyl chloride, polyurethane, copolymers of vinyl acetate and ethylene,polyamides, organic silicones, organofunctional silanes, unsaturatedpolyesters, epoxy resins, polyvinyl esters (such as polyvinylacetate orpolyvinylbutyrate latexes) and the like.

The organic binder, if present, may be included in the fire barrierlayer in an amount of from 0 to about 40 weight percent, in someembodiments from 0 to about 20 weight percent, based upon the totalweight of the fire barrier layer.

Solvents for the binders, if needed, can include water or a suitableorganic solvent, such as acetone, for the binder utilized. Solutionstrength of the binder in the solvent (if used) can be determined byconventional methods based on the binder loading desired and theworkability of the binder system (viscosity, solids content, etc.).

In certain embodiments, the fire barrier layer may comprise from about20% to about 100% by weight of the inorganic platelet material, from 0%to about 40% by weight of the organic binder and/or inorganic binder,and from 0% to about 50% of the functional filler.

In further embodiments, the fire barrier layer may comprise from about60% to about 100% by weight of the inorganic platelet material, from 0%to about 20% by weight of the organic binder and/or inorganic binder,and from 0% to about 20% of the functional filler.

The fire barrier film laminate and/or the fire barrier layer mayadditionally comprise a water repellant additive or coating. The waterrepellant additive or coating may be a component of the fire barrierlayer or may be a distinct coating or layer within the fire barrier filmlaminate, or may be saturated or impregnated into the fire barrierlayer. The water repellant additive may alternatively or additionally bepresent in the adhesives which may be utilized in the subject firebarrier laminate. Without limitation, the water repellant additive orcoating may comprise a water repellant silicone; a metal chloride saltsuch as calcium chloride, magnesium chloride, sodium chloride, potassiumchloride, or aluminum chloride; silane; fluorinated compounds orfluorosurfactants such as polytetrafluoroethylene resin; polymeric wetstrength resins such as polyamide resin or polyamide-epichlorohydrinresin; mixtures thereof, and the like.

The functional filler(s) may include, but not be limited to,non-platelet clays (such as attapulgite, kyanite, palygorskite,silimanite, or andalucite), fumed silica, boron nitride, cordierite andthe like. According to certain embodiments, the functional fillers mayinclude finely divided metal oxides, which may comprise at least one ofpyrogenic silicas, arc silicas, low-alkali precipitated silicas, fumedsilica, silicon dioxide aerogels, aluminum oxides, titania, calcia,magnesia, potassia, and mixtures thereof.

In certain embodiments, the functional filler may comprise endothermicfillers such as alumina trihydrate, magnesium carbonate, and otherhydrated inorganic materials including cements, hydrated zinc borate,calcium sulfate (gypsum), magnesium ammonium phosphate, magnesiumhydroxide and combinations thereof. In further embodiments, thefunctional filler(s) may include lithium-containing minerals. In stillfurther embodiments, the functional fillers(s) may include fluxingagents and/or fusing agents.

In certain embodiments, the functional filler may comprise fireretardant fillers such as antimony compounds, magnesium hydroxide,hydrated alumina compounds, borates, carbonates, bicarbonates, inorganichalides, phosphates, sulfates, organic halogens or organic phosphates.

The fire barrier layer may be directly or indirectly coated onto a film,for example, without limitation, by roll or reverse roll coating,gravure or reverse gravure coating, transfer coating, spray coating,brush coating, dip coating, tape casting, doctor blading, slot-diecoating, or deposition coating. In certain embodiments, the fire barrierlayer is coated onto the film as a slurry of the ingredients in asolvent, such as water, and is allowed to dry prior to incorporationinto the fire barrier laminate. The fire barrier layer may be created asa single layer or coating, thus utilizing a single pass, or may becreated by utilizing multiple passes, layers or coatings. By utilizingmultiple passes, the potential for formation of defects in the firebarrier layer is reduced. If multiple passes are desired, the second andpossible subsequent passes may be formed onto the first pass while thefirst pass is still substantially wet, i.e. prior to drying, such thatthe first and subsequent passes are able to form a single unitary firebarrier layer upon drying.

When multiple passes, layers or coatings of the fire barrier layer areutilized, it is possible to vary the amounts of the ingredients in eachpass, layer or coating, such that the passes, layers or coatings mayhave different amounts of, for example, inorganic platelet material. Incertain embodiments, at least one pass, layer or coating having agreater amount of inorganic platelet material may be present on the “hotface” of the fire barrier layer. Further, in certain embodiments anotherpass, layer or coating may have a greater amount of functional filler inorder to reduce the amount of defects present in the pass, layer orcoating, and may have a greater ability to correct defects present in aprevious pass, layer or coating.

In certain embodiments, the fire barrier layer may be directly orindirectly coated onto a first polymeric flame propagation resistantfilm, such as but not limited to polyesters, polyimides,polyetherketones, polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, combinations thereof, and the like.Commercially available examples of these films are films sold by E.I.DuPont de Nemours & Co. of Wilmington, Del., such as a polyester filmsold under the trade designation MYLAR®, a polyvinylfluoride film soldunder the trade designation TEDLAR®, and a polyimide film sold under thetrade designation KAPTON®, a polyetheretherketone film sold under thetrade designation APTIV® by Victrex, plc of Lancashire, UK, apolyetheretherketone film sold under the trade designation KETASPIRE®and an ethylene chlorotrifluoroethylene film sold under the tradedesignation HALAR® by Solvay SA of Brussels, Belgium, and the like. Thefirst polymeric flame propagation resistant film may be metalized tominimize moisture absorption, particularly on the outboard side, butoptionally on the inboard side also.

In certain embodiments, the first polymeric flame propagation resistantfilm and/or the metalized first polymeric flame propagation resistantfilm may have an opaque, low-gloss polymer coating, optionallycontaining a fire retardant additive. The fire retardant additives maycomprise at least one of antimony compounds, hydrated alumina compounds,borates, carbonates, bicarbonates, inorganic halides, phosphates,sulfates, organic halogens or organic phosphates.

The fire barrier laminate may additionally include an adhesive on one ofthe outer surfaces to facilitate thermal or other energetic bonding ofthe laminate to companion backside films as currently practiced in thefabrication of thermal acoustic insulation blankets to form a covering,bag, or envelope for the insulation layers. In some embodiments, apartially or substantially totally encapsulated insulation system isformed. (Air holes may be employed to accommodate pressure variationduring flight.) In certain embodiments, the adhesive comprises anadhesive which is activated by the application of ultrasonic or radiofrequency energy, or the like.

Optionally, at least one scrim layer may be disposed within the adhesiveor a surface adjacent to an adhesive on at least one side of, or within,the fire barrier laminate, in order to, for example, add strength to thelaminate, including puncture or tear resistance. In certain embodiments,a scrim may be disposed between the at least one non-fibrous firebarrier layer and the first polymeric flame propagation resistant filmlayer, such that the non-fibrous fire barrier layer may be coatedindirectly onto the flame propagation resistant film layer by coatingthe non-fibrous fire barrier layer onto the scrim. The scrim may be inthe form of a mesh, and may comprise fiberglass, nylon, polyester (suchas aromatic polyester), aramid (such as para-aramid), or high orultra-high molecular weight polyethylene in various embodiments, or maybe absent.

The fire barrier laminate may additionally include adhesives, internalto the fire barrier laminate, which are utilized to laminate orotherwise adhere the layers of the fire barrier laminate to one another.These adhesives may include thermally-activated or pressure-basedadhesives. The adhesives may comprise at least one of polyester basedadhesives or polyvinyl fluoride based adhesives, and/or siliconeadhesives. In certain embodiments, the adhesives may contain fireretardant additives. The fire retardant additives may comprise at leastone of antimony compounds, hydrated alumina compounds, borates,carbonates, bicarbonates, inorganic halides, phosphates, sulfates,organic halogens or organic phosphates.

As shown in FIG. 1A, an embodiment of a thermal acoustic insulationsystem 10, or “blanket”, is depicted in cross-section, in which twoinsulating layers 14, such as one inch thick MICROLITE AA® Premium NRfiberglass insulation (0.42 pcf) (available from Johns ManvilleInternational, Inc.), are disposed within a covering of an exteriorlyfacing fire barrier laminate 16, and an interiorly facing inboard coverfilm 18 (optionally, a second fire barrier laminate). The insulatinglayers 14 may also or alternatively comprise polyimide foam insulation.The exteriorly facing laminate 16 and the inboard film 18 may be heatsealed with an adhesive 12 to partially or substantially totally envelopor encapsulate the fiberglass insulation layers. Flames 20, depictingthe FAA test procedures, are shown proximate to the exteriorly facingfire barrier laminate 16.

A detail section of an embodiment of the fire barrier laminate 16,encircled as B′ in FIG. 1A is shown in an exploded cross-sectional viewin FIG. 1B. The fire barrier laminate 16 is constructed by firstapplying an adhesive 104 to a first polymeric flame propagationresistant film 106, such as a polyetheretherketone film. The firebarrier layer 102 is then coated onto the adhesive 104-coated firstpolymeric film 106. Alternatively, the adhesive 104 may be omitted,resulting in the fire barrier layer 102 being coated directly onto thefirst polymeric film 106. The fire barrier layer 102 may comprise apaste or slurry type material with an amount of water or other solventbeing present in the fire barrier layer 102 as it is being coated ontothe first polymeric film 106. In this instance, the fire barrier layer102 is allowed to dry before continued processing. Optionally, awater-repellant material may be incorporated in, coated onto orsaturated/impregnated into the fire barrier layer 102.

Separately, a scrim layer 108, such as a fiberglass or nylon scrim, islaminated to a second film 110, such as a polyetheretherketone film,using an adhesive 114. An adhesive 112 is also used to laminate the firebarrier layer 102-coated first polymeric film 106 to the scrim layer108. Alternatively, the scrim layer 108 may be adhered to the firebarrier layer 102 prior to laminating the scrim layer 108 to the secondfilm 110.

Optionally, the assembled fire barrier laminate 16 includes anencapsulating adhesive layer 116 adjacent to the first polymeric film106 in order to encapsulate the insulation layers 14 between the firebarrier laminate 16 and the inboard film 18. Additionally oralternatively, the fire barrier laminate 16 may utilize mechanicalfasteners or tapes for encapsulating the insulating layers 14 betweenthe fire barrier laminate 16 and the inboard film 18.

A detail section of another embodiment of the fire barrier laminate 16,encircled as B′ in FIG. 1A is shown in an exploded cross-sectional viewin FIG. 1C. The fire barrier laminate 16 is constructed by firstapplying an adhesive 204 to a first polymeric flame propagationresistant film 206, such as a ethylene chlorotrifluoroethylene film. Thefire barrier layer 202 is then coated onto the adhesive 204-coated firstpolymeric film 206. Alternatively, the adhesive 204 may be omitted,resulting in the fire barrier layer 202 being coated directly onto thefirst polymeric film 206. The fire barrier layer 202 may comprise apaste or slurry type material with an amount of water or other solventbeing present in the fire barrier layer 202 as it is being coated ontothe first polymeric film 206. In this instance, the fire barrier layer202 is allowed to dry before continued processing. Optionally, awater-repellant material may be incorporated in, coated onto orsaturated/impregnated into the fire barrier layer 202.

A second film 210, such as a metalized polyetheretherketone film, islaminated to the fire barrier layer 202-coated first polymeric film 206using an adhesive 212. The fire barrier laminate 16 includes a scrimlayer 208 laminated to the first polymeric film 206 opposite the firebarrier layer 202 via an adhesive layer 216.

A detail section of a further embodiment of the fire barrier laminate16, encircled as B′ in FIG. 1A is shown in an exploded cross-sectionalview in FIG. 1D. The fire barrier laminate 16 is constructed by firstapplying an adhesive 304 to a first polymeric flame propagationresistant film 306, such as a metalized polyetheretherketone film. Thefire barrier layer 302 is then coated onto the adhesive 304-coated firstpolymeric film 306. Alternatively, the adhesive 304 may be omitted,resulting in the fire barrier layer 302 being coated directly onto thefirst polymeric film 306. The fire barrier layer 302 may comprise apaste or slurry type material with an amount of water or other solventbeing present in the fire barrier layer 302 as it is being coated ontothe first polymeric film 306. In this instance, the fire barrier layer302 is allowed to dry before continued processing. Optionally, awater-repellant material may be incorporated in, coated onto orsaturated/impregnated into the fire barrier layer 302.

Separately, a scrim layer 308, such as a fiberglass or nylon scrim, islaminated to a second film 310, such as a polyetheretherketone film. Anadhesive 312 is also used to laminate the fire barrier layer 302-coatedfirst polymeric film 306 to the scrim layer 308. Alternatively, thescrim layer 308 may be adhered to the fire barrier layer 302 prior tolaminating the scrim layer 308 to the second film 310.

The assembled fire barrier laminate 16 may include an encapsulatingadhesive layer 316 adjacent to the first polymeric film 306 in order toencapsulate the insulation layers 14 between the fire barrier laminate16 and the inboard film 18. A second scrim layer 308 a is optionallyembedded in the adhesive layer 316.

A detail section of a further embodiment of the fire barrier laminate16, encircled as B′ in FIG. 1A is shown in an exploded cross-sectionalview in FIG. 1E. The fire barrier laminate 16 is constructed by firstapplying an adhesive 404 to a first polymeric flame propagationresistant film 406, such as a polyetheretherketone film. A second scrimlayer 408 a is optionally laminated between the adhesive 404 and thefirst polymeric film 406. The fire barrier layer 402 is then coated ontothe adhesive 404-coated first polymeric film 406. Alternatively, theadhesive 404 may be omitted, resulting in the fire barrier layer 402being coated directly onto the first polymeric film 406. The firebarrier layer 402 may comprise a paste or slurry type material with anamount of water or other solvent being present in the fire barrier layer402 as it is being coated onto the first polymeric film 406. In thisinstance, the fire barrier layer 402 is allowed to dry before continuedprocessing. Optionally, a water-repellant material may be incorporatedin, coated onto or saturated/impregnated into the fire barrier layer402.

A second film 410, such as a metalized polyetheretherketone film, islaminated to the fire barrier layer 402-coated first polymeric film 406using an adhesive 412. The fire barrier laminate 16 includes a scrimlayer 408 laminated to the first polymeric film 406 opposite the firebarrier layer 402 via an adhesive layer 416.

The following examples are set forth merely to further illustrate thesubject fire barrier layer and fire barrier film laminate. Theillustrative examples should not be construed as limiting the firebarrier layer and/or fire barrier laminate in any manner.

Sample 1 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film which had previouslybeen coated with a silicone adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a siliconelaminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film. Thefire barrier laminate final construction had a basis weight of 97 gsmand passed the test protocols of 14 C.F.R. §25.856(a) and (b), describedbelow.

Sample 2 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes and water. The fire barrier layer was applied to apolyetheretherketone (PEEK) film which had previously been coated with amodified natural rubber adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a poly(amide)laminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film anda fiberglass scrim was incorporated onto the heat seal adhesive-coatedface. The fire barrier laminate final construction had a basis weight of90 gsm and passed the test protocols of 14 C.F.R. §25.856(a) and (b),described below.

Sample 3 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film which had previouslybeen coated with a modified natural rubber adhesive and allowed to dry.Separately, a second PEEK film was laminated to a nylon scrim using apoly(amide) laminating adhesive. The scrim side of the laminate waslaminated to the fire barrier layer side of the fire barrierlayer-coated PEEK film to form a fire barrier laminate. A heat sealadhesive was then applied to the face of the fire barrier laminateopposite the second PEEK film. The fire barrier laminate finalconstruction had a basis weight of 103 gsm and passed the test protocolsof 14 C.F.R. §25.856(a) and (b), described below.

Sample 4 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes, silicone binder and water. The fire barrier layerwas applied to a polyetheretherketone (PEEK) film which had previouslybeen coated with a modified natural rubber adhesive and allowed to dry.Separately, an ethylene chlorotrifluoroethylene (ECTFE) film waslaminated to a nylon scrim using a silicone laminating adhesive. Thescrim side of the laminate was laminated to the fire barrier layer sideof the fire barrier layer-coated PEEK film to form a fire barrierlaminate. A heat seal adhesive was then applied to the external face ofthe ECTFE film. The fire barrier laminate final construction had a basisweight of 95 gsm and passed the test protocols of 14 C.F.R. §25.856(a)and (b), described below.

Sample 5 comprised a fire barrier layer containing suspended exfoliatedvermiculite flakes and water. The fire barrier layer was applied to apolyetheretherketone (PEEK) film which had previously been coated with amodified natural rubber adhesive and allowed to dry. Separately, asecond PEEK film was laminated to a nylon scrim using a siliconelaminating adhesive. The scrim side of the laminate was laminated to thefire barrier layer side of the fire barrier layer-coated PEEK film toform a fire barrier laminate. A heat seal adhesive was then applied tothe face of the fire barrier laminate opposite the second PEEK film anda nylon scrim was incorporated onto the heat seal adhesive-coated face.The fire barrier laminate final construction had a basis weight of 105gsm and passed the test protocols of 14 C.F.R. §25.856(a) and (b),described below.

For testing according to 14 C.F.R. §25.856(a), the fire barrier laminateof each of the Samples 1-5 was used to encapsulate two (2) 1 inch layersof 0.34 pcf MICROLITE AA® premium fiberglass insulation with LAMAGUARD®131 MD companion polymer film. The fire barrier laminate was heat sealedin order to encapsulate the fiberglass insulation.

For testing according to 14 C.F.R. §25.856(b) the fire barrier laminateof each of the Samples 1-5 was used to encapsulate one (1) 1 inch layerof 0.34 pcf MICROLITE AA® premium fiberglass insulation with LAMAGUARD®131 MD companion polymer film. The fire barrier laminate wasmechanically sealed using staples in order to encapsulate the fiberglassinsulation.

Test Protocols

The fire barrier film laminate-protected thermal/acoustic insulationblankets described above were tested according to the protocols of 14C.F.R. §25.856(a) and (b), Appendix F, Parts VI and VII, which areincorporated herein in their entirety, as if fully written out below.

14 C.F.R. §25.856(a) and (b) provide in pertinent part:

TABLE 2 § 25.856 Thermal/Acoustic insulation materials. (a)Thermal/acoustic insulation material installed in the fuselage must meetthe flame propagation test requirements of part VI of Appendix F to thispart, or other approved equivalent test requirements. (b) For airplaneswith a passenger capacity of 20 or greater, thermal/ acoustic insulationmaterials (including the means of fastening the materials to thefuselage) installed in the lower half of the airplane fuselage must meetthe flame penetration resistance test requirements of part VII ofAppendix F to this part, or other approved equivalent test requirements.

Appendix F Part VI provides, in pertinent part:

TABLE 3 Part VI -- Test Method To Determine the Flammability and FlamePropagation Characteristics of Thermal/Acoustic Insulation Materials Usethis test method to evaluate the flammability and flame propagationcharacteristics of thermal/acoustic insulation when exposed to both aradiant heat source and a flame. (a) Definitions. “Flame propagation”means the furthest distance of the propagation of visible flame towardsthe far end of the test specimen, measured from the midpoint of theignition source flame. Measure this distance after initially applyingthe ignition source and before all flame on the test specimen isextinguished. The measurement is not a determination of burn length madeafter the test. “Radiant heat source” means an electric or air propanepanel. “Thermal/acoustic insulation” means a material or system ofmaterials used to provide thermal and/or acoustic protection. Examplesinclude fiberglass or other batting material encapsulated by a filmcovering and foams. “Zero point” means the point of application of thepilot burner to the test specimen. (b) Test apparatus. (4) Pilot Burner.The pilot burner used to ignite the specimen must be a Bernzomatic ™commercial propane venturi torch with an axially symmetric burner tipand a propane supply tube with an orifice diameter of 0.006 inches (0.15mm). The length of the burner tube must be 2⅞ inches (71 mm). Thepropane flow must be adjusted via gas pressure through an in-lineregulator to produce a blue inner cone length of ¾ inch (19 mm). A ¾inch (19 mm) guide (such as a thin strip of metal) may be soldered tothe top of the burner to aid in setting the flame height. The overallflame length must be approximately 5 inches long (127 mm). Provide a wayto move the burner out of the ignition position so that the flame ishorizontal and at least 2 inches (50 mm) above the specimen plane. (5)Thermocouples. Install a 24 American Wire Gauge (AWG) Type K(Chromel-Alumel) thermocouple in the test chamber for temperaturemonitoring. Insert it into the chamber through a small hole drilledthrough the back of the chamber. Place the thermocouple so that itextends 11 inches (279 mm) out from the back of the chamber wall, 11½inches (292 mm) from the right side of the chamber wall, and is 2 inches(51 mm) below the radiant panel. The use of other thermocouples isoptional. (6) Calorimeter. The calorimeter must be a one-inchcylindrical water-cooled, total heat flux density, foil type Gardon Gagethat has a range of 0 to 5 BTU/ft²-second (0 to 5.7 Watts/cm²). (c) Testspecimens. (1) Specimen preparation. Prepare and test a minimum of threetest specimens. If an oriented film cover material is used, prepare andtest both the warp and fill directions. (2) Construction. Test specimensmust include all materials used in construction of the insulation(including batting, film, scrim, tape etc.). Cut a piece of corematerial such as foam or fiberglass, and cut a piece of film covermaterial (if used) large enough to cover the core material. Heat sealingis the preferred method of preparing fiberglass samples, since they canbe made without compressing the fiberglass (“box sample”). Covermaterials that are not heat scalable may be stapled, sewn, or taped aslong as the cover material is over-cut enough to be drawn down the sideswithout compressing the core material. The fastening means should be ascontinuous as possible along the length of the seams. The specimenthickness must be of the same thickness as installed in the airplane.(3) Specimen Dimensions. To facilitate proper placement of specimens inthe sliding platform housing, cut non-rigid core materials, such asfiberglass, 12½ inches (318 mm) wide by 23 inches (584 mm) long. Cutrigid materials, such as foam, 11½ ± ¼ inches (292 mm ± 6 mm) wide by 23inches (584 mm) long in order to fit properly in the sliding platformhousing and provide a flat, exposed surface equal to the opening in thehousing. (d) Specimen conditioning. Condition the test specimens at 70 ±5° F. (21° ± 2° C.) and 55% ± 10% relative humidity, for a minimum of 24hours prior to testing. (f) Test Procedure. (1) Ignite the pilot burner.Ensure that it is at least 2 inches (51 mm) above the top of theplatform. The burner must not contact the specimen until the testbegins. (2) Place the test specimen in the sliding platform holder.Ensure that the test sample surface is level with the top of theplatform. At “zero” point, the specimen surface must be 7½ inches ± ⅛inch (191 mm ± 3) below the radiant panel. (3) Place theretaining/securing frame over the test specimen. It may be necessary(due to compression) to adjust the sample (up or down) in order tomaintain the distance from the sample to the radiant panel (7½ inches ±⅛ inch (191 mm ± 3) at “zero” position). With film/fiberglassassemblies, it is critical to make a slit in the film cover to purge anyair inside. This allows the operator to maintain the proper testspecimen position (level with the top of the platform) and to allowventilation of gases during testing. A longitudinal slit, approximately2 inches (51 mm) in length, must be centered 3 inches ± ½ inch (76 mm ±13 mm) from the left flange of the securing frame. A utility knife isacceptable for slitting the film cover. (4) Immediately push the slidingplatform into the chamber and close the bottom door. (5) Bring the pilotburner flame into contact with the center of the specimen at the “zero”point and simultaneously start the timer. The pilot burner must be at a27° angle with the sample and be approximately ½ inch (12 mm) above thesample. A stop . . . allows the operator to position the burnercorrectly each time. (6) Leave the burner in position for 15 seconds andthen remove to a position at least 2 inches (51 mm) above the specimen.(g) Report. (1) Identify and describe the test specimen. (2) Report anyshrinkage or melting of the test specimen. (3) Report the flamepropagation distance. If this distance is less than 2 inches, reportthis as a pass (no measurement required). (4) Report the after-flametime. (h) Requirements. (1) There must be no flame propagation beyond 2inches (51 mm) to the left of the centerline of the pilot flameapplication. (2) The flame time after removal of the pilot burner maynot exceed 3 seconds on any specimen.

Appendix F Part VII provides, in pertinent part:

TABLE 4 Part VII -- Test Method To Determine the Burnthrough Resistanceof Thermal/Acoustic Insulation Materials Use the following test methodto evaluate the burnthrough resistance characteristics of aircraftthermal/acoustic insulation materials when exposed to a high intensityopen flame. (a) Definitions. Burnthrough time means the time, inseconds, for the burner flame to penetrate the test specimen, and/or thetime required for the heat flux to reach 2.0 Btu/ft²sec (2.27 W/cm²) onthe inboard side, at a distance of 12 inches (30.5 cm) from the frontsurface of the insulation blanket test frame, whichever is sooner. Theburnthrough time is measured at the inboard side of each of theinsulation blanket specimens. Insulation blanket specimen means one oftwo specimens positioned in either side of the test rig, at an angle of30° with respect to vertical. Specimen set means two insulation blanketspecimens. Both specimens must represent the same production insulationblanket construction and materials, proportioned to correspond to thespecimen size. (b) Apparatus. (3) Calibration rig and equipment. (i)Construct individual calibration rigs to incorporate a calorimeter andthermocouple rake for the measurement of heat flux and temperature.Position the calibration rigs to allow movement of the burner from thetest rig position to either the heat flux or temperature position withminimal difficulty. (ii) Calorimeter. The calorimeter must be a totalheat flux, foil type Gardon Gage of an appropriate range such as 0-20Btu/ft²-sec (0-22.7 W/cm²), accurate to ±3% of the indicated reading.The heat flux calibration method must be in accordance with paragraphVI(b)(7) of this appendix. (iv) Thermocouples. Provide seven ⅛-inch (3.2mm) ceramic packed, metal sheathed, type K (Chromel-alumel), groundedjunction thermocouples with a nominal 24 American Wire Gauge (AWG) sizeconductor for calibration. Attach the thermocouples to a steel anglebracket to form a thermocouple rake for placement in the calibration rigduring burner calibration. (5) Backface calorimeters. Mount two totalheat flux Gardon type calorimeters behind the insulation test specimenson the back side (cold) area of the test specimen mounting frame.Position the calorimeters along the same plane as the burner conecenterline, at a distance of 4 inches (102 mm) from the verticalcenterline of the test frame. (i) The calorimeters must be a total heatflux, foil type Gardon Gage of an appropriate range such as 0-5Btu/ft²-sec (0-5.7 W/cm²), accurate to ±3% of the indicated reading. Theheat flux calibration method must comply with paragraph VI(b)(7) of thisappendix. (6) Instrumentation. Provide a recording potentiometer orother suitable calibrated instrument with an appropriate range tomeasure and record the outputs of the calorimeter and the thermocouples.(7) Timing device. Provide a stopwatch or other device, accurate to ±1%,to measure the time of application of the burner flame and burnthroughtime. (c) Test Specimens. (1) Specimen preparation. Prepare a minimum ofthree specimen sets of the same construction and configuration fortesting. (2) Insulation blanket test specimen. (i) For batt-typematerials such as fiberglass, the constructed, finished blanket specimenassemblies must be 32 inches wide by 36 inches long (81.3 by 91.4 cm),exclusive of heat sealed film edges. (3) Construction. Make each of thespecimens tested using the principal components (i.e., insulation, firebarrier material if used, and moisture barrier film) and assemblyprocesses (representative seams and closures). (i) Fire barriermaterial. If the insulation blanket is constructed with a fire barriermaterial, place the fire barrier material in a manner reflective of theinstalled arrangement For example, if the material will be placed on theoutboard side of the insulation material, inside the moisture film,place it the same way in the test specimen. (v) Conditioning. Conditionthe specimens at 70° ± 5° F. (21° ± 2° C.) and 55% ± 10% relativehumidity for a minimum of 24 hours prior to testing. (f) Test procedure.(1) Secure the two insulation blanket test specimens to the test frame.The insulation blankets should be attached to the test rig centervertical former using four spring clamps . . . (according to thecriteria of paragraph (c)(4) or (c)(4)(i) of this part of thisappendix). (2) Ensure that the vertical plane of the burner cone is at adistance of 4 ± 0.125 inch (102 ± 3 mm) from the outer surface of thehorizontal stringers of the test specimen frame, and that the burner andtest frame are both situated at a 30° angle with respect to vertical.(3) When ready to begin the test, direct the burner away from the testposition to the warm-up position so that the flame will not impinge onthe specimens prematurely. Turn on and light the burner and allow it tostabilize for 2 minutes. (4) To begin the test, rotate the burner intothe test position and simultaneously start the timing device. (5) Exposethe test specimens to the burner flame for 4 minutes and then turn offthe burner. Immediately rotate the burner out of the test position. (6)Determine (where applicable) the burnthrough time, or the point at whichthe heat flux exceeds 2.0 Btu/ft²-sec (2.27 W/cm²). (g) Report. (1)Identify and describe the specimen being tested. (2) Report the numberof insulation blanket specimens tested. (3) Report the burnthrough time(if any), and the maximum heat flux on the back face of the insulationblanket test specimen, and the time at which the maximum occurred. (h)Requirements. (1) Each of the two insulation blanket test specimens mustnot allow fire or flame penetration in less than 4 minutes. (2) Each ofthe two insulation blanket test specimens must not allow more than 2.0Btu/ft²-sec (2.27 W/cm²) on the cold side of the insulation specimens ata point 12 inches (30.5 cm) from the face of the test rig.

In a first embodiment, a subject fire barrier laminate may comprise: atleast one non-fibrous fire barrier layer directly or indirectly coatedonto at least one first polymeric flame propagation resistant filmlayer; at least one second film layer proximate to the non-fibrous firebarrier layer opposite the first polymeric flame propagation resistantfilm layer; at least one scrim layer disposed: (i) between thenon-fibrous fire barrier layer and the first polymeric flame propagationresistant film layer; and/or (ii) between the non-fibrous fire barrierlayer and the second film layer; and/or (iii) proximate to the firstpolymeric flame propagation resistant film layer opposite thenon-fibrous fire barrier layer; and/or (iv) proximate to the second filmlayer opposite the non-fibrous fire barrier layer; optionally, awater-repellant material incorporated into and/or applied to thenon-fibrous fire barrier layer; optionally at least one adhesive layeradhering the non-fibrous fire barrier layer to the first polymeric flamepropagation resistant film layer; and optionally at least one adhesivelayer adhering the scrim layer to at least one of the non-fibrous firebarrier layer, the first polymeric flame propagation resistant filmlayer, or the second film layer; wherein the non-fibrous fire barrierlayer comprises at least one inorganic platelet material, optionally atleast one organic binder and/or inorganic binder, and optionally atleast one functional filler.

The fire barrier laminate of the first embodiment may further includethat the inorganic platelet material comprises at least one ofvermiculite, mica, clay or talc. The vermiculite may be exfoliated andoptionally defoliated. The clay may comprise at least one of ball clay,bentonite, smectite, hectorite, kaolinite, montmorillonite, saponite,sepiolite or sauconite.

The fire barrier laminate of either or both of the first or subsequentembodiments may further include that the organic binder comprises atleast one of acrylic latex, (meth)acrylic latex, phenolic resins,copolymers of styrene and butadiene, vinylpyridine, acrylonitrile,copolymers of acrylonitrile and styrene, vinyl chloride, polyurethane,copolymers of vinyl acetate and ethylene, polyamides, silicones,unsaturated polyesters, epoxy resins or polyvinyl esters.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the inorganic binder comprises at least one ofcolloidal alumina, colloidal silica or colloidal zirconia.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the non-fibrous fire barrier layer comprisesfrom about 20% to about 100% by weight of the inorganic plateletmaterial, from 0% to about 40% by weight of the organic binder and/orinorganic binder, and from 0% to about 50% of the functional filler.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the non-fibrous fire barrier layer comprisesfrom about 60% to about 100% by weight of the inorganic plateletmaterial, from 0% to about 20% by weight of the organic binder and/orinorganic binder, and from 0% to about 20% of the functional filler.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that either or both of the first polymeric flamepropagation resistant film layer or the second film layer comprises atleast one of polyesters, polyimides, polyetherketones,polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, or combinations thereof.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that the at least one scrim layer comprises at leastone of fiberglass, nylon, polyester, aramid, or high or ultra-highmolecular weight polyethylene.

The fire barrier laminate of any of the first or subsequent embodimentsmay further include that either or both of the first polymeric flamepropagation resistant film layer and the second film layer aremetalized. Either or both of the first polymeric flame propagationresistant film layer or the second film layer have an opaque, low-glosspolymer coating, optionally including a fire retardant additive.

The fire barrier laminate of any of the first or subsequent embodimentsmay have a basis weight of less than about 120 gsm.

In a second embodiment, a subject thermal acoustic insulation system maycomprise a plurality of insulating layers disposed within a covering ofan exteriorly facing fire barrier laminate as in any of the first orsubsequent embodiments, and an interiorly facing inboard cover film.

The thermal acoustic insulation system of the second embodiment mayfurther include that the interiorly facing cover film also comprises thefire barrier laminate.

The thermal acoustic insulation system of either or both of the secondor subsequent embodiments may further include that the exteriorly facingfire barrier laminate and the interiorly facing inboard cover film aresealed with an adhesive to partially or substantially totally envelop orencapsulate the plurality of insulating layers.

The thermal acoustic insulation system of any of the second orsubsequent embodiments may further include that the insulating layerscomprise fiberglass insulation and/or polyimide foam insulation.

The thermal acoustic insulation system of any of the second orsubsequent embodiments may be capable of passing the flame propagationand burn-through resistance test protocols of 14 C.F.R. §25.856(a) and(b), Appendix F, Parts VI and VII.

In a third embodiment, a subject method of making a fire barrierlaminate may comprise: directly or indirectly coating at least onenon-fibrous fire barrier layer onto a first polymeric flame propagationresistant film layer; laminating the non-fibrous fire barrier layer withat least one second film layer, wherein the second film layer isproximate to the non-fibrous fire barrier layer; and laminating at leastone scrim layer within the fire barrier laminate, wherein the at leastone scrim layer is disposed: (i) between the non-fibrous fire barrierlayer and the first polymeric flame propagation resistant film layer;and/or (ii) between the non-fibrous fire barrier layer and the secondfilm layer; and/or (iii) proximate to the first polymeric flamepropagation resistant film layer opposite the non-fibrous fire barrierlayer; and/or (iv) proximate to the second film layer opposite thenon-fibrous fire barrier layer; wherein the non-fibrous fire barrierlayer comprises at least one inorganic platelet material, optionally atleast one organic binder and/or inorganic binder, and optionally atleast one functional filler; and wherein the non-fibrous fire barrierlayer optionally contains a water repellant material, and/or the methodfurther comprises optionally coating and/or saturating the non-fibrousfire barrier layer with a water repellant material.

The method of the third embodiment may further include that theinorganic platelet material comprises at least one of vermiculite, mica,clay or talc. The vermiculite may be exfoliated and optionallydefoliated.

The method of either or both of the third or subsequent embodiments mayfurther include that the organic binder comprises at least one ofacrylic latex, (meth)acrylic latex, phenolic resins, copolymers ofstyrene and butadiene, vinylpyridine, acrylonitrile, copolymers ofacrylonitrile and styrene, vinyl chloride, polyurethane, copolymers ofvinyl acetate and ethylene, polyamides, silicones, unsaturatedpolyesters, epoxy resins or polyvinyl esters.

The method of any of the third or subsequent embodiments may furtherinclude that the inorganic binder comprises at least one of colloidalalumina, colloidal silica or colloidal zirconia.

The method of any of the third or subsequent embodiments may furtherinclude that the non-fibrous fire barrier layer comprises from about 20%to about 100% by weight of the inorganic platelet material, from 0% toabout 40% by weight of the organic binder and/or inorganic binder, andfrom 0% to about 50% of the functional filler.

The method of any of the third or subsequent embodiments may furtherinclude that either or both of the first polymeric flame propagationresistant film layer or the second film layer comprises at least one ofpolyesters, polyimides, polyetherketones, polyetheretherketones,polyvinylfluorides, polyamides, polytetrafluoroethylenes, polyarylsulfones, polyester amides, polyester imides, polyethersulfones,polyphenylene sulfides, ethylene chlorotrifluoroethylene, orcombinations thereof.

The method of any of the third or subsequent embodiments may furtherinclude that the at least one scrim layer comprises at least one offiberglass, nylon, polyester, aramid, or high or ultra-high molecularweight polyethylene.

The method of any of the third or subsequent embodiments may furtherinclude that either or both of the first polymeric flame propagationresistant film layer or the second film layer are metalized. Either orboth of the first polymeric flame propagation resistant film layer orthe second film layer may be coated with an opaque, low-gloss polymer,optionally including a fire retardant additive.

It will be understood that the embodiments described herein are merelyexemplary, and that one skilled in the art may make variations andmodifications without departing from the spirit and scope of theinvention. All such variations and modifications are intended to beincluded within the scope of the invention as described hereinabove.Further, all embodiments disclosed are not necessarily in thealternative, as various embodiments of the invention may be combined toprovide the desired result.

1. A fire barrier laminate comprising: at least one non-fibrous firebarrier layer directly or indirectly coated onto at least one firstpolymeric flame propagation resistant film layer; at least one secondfilm layer proximate to the non-fibrous fire barrier layer opposite thefirst polymeric flame propagation resistant film layer; at least onescrim layer disposed: (i) between the non-fibrous fire barrier layer andthe first polymeric flame propagation resistant film layer; and/or (ii)between the non-fibrous fire barrier layer and the second film layer;and/or (iii) proximate to the first polymeric flame propagationresistant film layer opposite the non-fibrous fire barrier layer; and/or(iv) proximate to the second film layer opposite the non-fibrous firebarrier layer; optionally, a water-repellant material incorporated intoand/or applied to the non-fibrous fire barrier layer; optionally atleast one adhesive layer adhering the non-fibrous fire barrier layer tothe first polymeric flame propagation resistant film layer; andoptionally at least one adhesive layer adhering the scrim layer to atleast one of the non-fibrous fire barrier layer, the first polymericflame propagation resistant film layer, or the second film layer;wherein the non-fibrous fire barrier layer comprises at least oneinorganic platelet material, optionally at least one organic binderand/or inorganic binder, and optionally at least one functional filler.2. The fire barrier laminate of claim 1, wherein the inorganic plateletmaterial comprises at least one of vermiculite, mica, clay or talc. 3.The fire barrier laminate of claim 2, wherein the vermiculite isexfoliated and optionally defoliated.
 4. The fire barrier laminate ofclaim 2, wherein the clay comprises at least one of ball clay,bentonite, smectite, hectorite, kaolinite, montmorillonite, saponite,sepiolite or sauconite.
 5. The fire barrier laminate of claim 1, whereinthe organic binder comprises at least one of acrylic latex,(meth)acrylic latex, phenolic resins, copolymers of styrene andbutadiene, vinylpyridine, acrylonitrile, copolymers of acrylonitrile andstyrene, vinyl chloride, polyurethane, copolymers of vinyl acetate andethylene, polyamides, silicones, unsaturated polyesters, epoxy resins orpolyvinyl esters.
 6. The fire barrier laminate of claim 1, wherein theinorganic binder comprises at least one of colloidal alumina, colloidalsilica or colloidal zirconia.
 7. The fire barrier laminate of claim 1,wherein the non-fibrous fire barrier layer comprises from about 20% toabout 100% by weight of the inorganic platelet material, from 0% toabout 40% by weight of the organic binder and/or inorganic binder, andfrom 0% to about 50% of the functional filler.
 8. The fire barrierlaminate of claim 1, wherein the non-fibrous fire barrier layercomprises from about 60% to about 100% by weight of the inorganicplatelet material, from 0% to about 20% by weight of the organic binderand/or inorganic binder, and from 0% to about 20% of the functionalfiller.
 9. The fire barrier laminate of claim 1, wherein either or bothof the first polymeric flame propagation resistant film layer or thesecond film layer comprises at least one of polyesters, polyimides,polyetherketones, polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, or combinations thereof.
 10. The fire barrierlaminate of claim 1, wherein the at least one scrim layer comprises atleast one of fiberglass, nylon, polyester, aramid, or high or ultra-highmolecular weight polyethylene.
 11. The fire barrier laminate of claim 1,wherein either or both of the first polymeric flame propagationresistant film layer and the second film layer are metalized.
 12. Thefire barrier laminate of claim 11, wherein either or both of the firstpolymeric flame propagation resistant film layer or the second filmlayer have an opaque, low-gloss polymer coating, optionally including afire retardant additive.
 13. The fire barrier laminate of claim 1 havinga basis weight of less than about 120 gsm.
 14. A thermal acousticinsulation system comprising a plurality of insulating layers disposedwithin a covering of an exteriorly facing fire barrier laminate as inclaim 1, and an interiorly facing inboard cover film.
 15. The thermalacoustic insulation system of claim 14, wherein the interiorly facingcover film also comprises the fire barrier laminate.
 16. The thermalacoustic insulation system of claim 14, wherein the exteriorly facingfire barrier laminate and the interiorly facing inboard cover film aresealed with an adhesive to partially or substantially totally envelop orencapsulate the plurality of insulating layers.
 17. The thermal acousticinsulation system of claim 14, wherein the insulating layers comprisefiberglass insulation and/or polyimide foam insulation.
 18. The thermalacoustic insulation system of claim 14 capable of passing the flamepropagation and burn-through resistance test protocols of 14 C.F.R.§25.856(a) and (b), Appendix F, Parts VI and VII.
 19. A method of makinga fire barrier laminate comprising: directly or indirectly coating atleast one non-fibrous fire barrier layer onto a first polymeric flamepropagation resistant film layer; laminating the non-fibrous firebarrier layer with at least one second film layer, wherein the secondfilm layer is proximate to the non-fibrous fire barrier layer; andlaminating at least one scrim layer with the fire barrier laminate,wherein the at least one scrim layer is disposed: (i) between thenon-fibrous fire barrier layer and the first polymeric flame propagationresistant film layer; and/or (ii) between the non-fibrous fire barrierlayer and the second film layer; and/or (iii) proximate to the firstpolymeric flame propagation resistant film layer opposite thenon-fibrous fire barrier layer; and/or (iv) proximate to the second filmlayer opposite the non-fibrous fire barrier layer; wherein thenon-fibrous fire barrier layer comprises at least one inorganic plateletmaterial, optionally at least one organic binder and/or inorganicbinder, and optionally at least one functional filler; and wherein thenon-fibrous fire barrier layer optionally contains a water-repellantmaterial, and/or the method further comprises optionally coating and/orsaturating the non-fibrous fire barrier layer with a water-repellantmaterial.
 20. The method of claim 19, wherein the inorganic plateletmaterial comprises at least one of vermiculite, mica, clay or talc. 21.The method of claim 20, wherein the vermiculite is exfoliated andoptionally defoliated.
 22. The method of claim 19, wherein the organicbinder comprises at least one of acrylic latex, (meth)acrylic latex,phenolic resins, copolymers of styrene and butadiene, vinylpyridine,acrylonitrile, copolymers of acrylonitrile and styrene, vinyl chloride,polyurethane, copolymers of vinyl acetate and ethylene, polyamides,silicones, unsaturated polyesters, epoxy resins or polyvinyl esters. 23.The method of claim 19, wherein the inorganic binder comprises at leastone of colloidal alumina, colloidal silica or colloidal zirconia. 24.The method of claim 19, wherein the non-fibrous fire barrier layercomprises from about 20% to about 100% by weight of the inorganicplatelet material, from 0% to about 40% by weight of the organic binderand/or inorganic binder, and from 0% to about 50% of the functionalfiller.
 25. The method of claim 19, wherein either or both of the firstpolymeric flame propagation resistant film layer or the second filmlayer comprises at least one of polyesters, polyimides,polyetherketones, polyetheretherketones, polyvinylfluorides, polyamides,polytetrafluoroethylenes, polyaryl sulfones, polyester amides, polyesterimides, polyethersulfones, polyphenylene sulfides, ethylenechlorotrifluoroethylene, or combinations thereof.
 26. The method ofclaim 19, wherein the at least one scrim layer comprises at least one offiberglass, nylon, polyester, aramid, or high or ultra-high molecularweight polyethylene.
 27. The method of claim 19, wherein either or bothof the first polymeric flame propagation resistant film layer or thesecond film layer are metalized.
 28. The method of claim 27, furthercomprising coating either or both of the first polymeric flamepropagation resistant film layer or the second film layer with anopaque, low-gloss polymer, optionally including a fire retardantadditive.